Structural Door

ABSTRACT

A structural door module for a motor vehicle door body includes a carrier plate forming a first and second surface. The structural door module also includes a plurality of door hardware components mounted to at least one of the first and second surface in a pre-configured orientation. A handle support is integrally formed from the carrier plate, and provides a cavity to receive a door handle assembly on the first surface.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.13/172,032 filed Jun. 29, 2011 which is a divisional of U.S. applicationSer. No. 11/629,426 filed Dec. 13, 2006, now U.S. Pat. No. 7,992,347,which claims the benefit and priority of International Application No.PCT/CA2005/000956 filed Jun. 21, 2005 which claims the benefit of U.S.Provisional Application No. 60/582,300 filed Jun. 23, 2004.

FIELD OF THE INVENTION

The present invention relates to a module for a motor vehicle door body.More particularly, the present invention relates to a structural modulethat both strengthens the motor vehicle door body and acts as a hardwarecarrier for hardware subsystems in order to minimize subsequent assemblyoperations.

BACKGROUND OF THE INVENTION

A motor vehicle door typically includes an outer sheet metal panel, aninner sheet metal panel, and a plurality of hardware components mountedwithin an inner cavity formed between the outer and inner sheet metalpanels. Common hardware components mounted to a door body include innerand outer door handle assemblies, window regulators, latch assembliesand speaker assemblies, along with their ancillary connecting andelectrical components. The complete assembly of the door involvesmultiple manufacturing steps and numerous parts. Conventionally, anoriginal equipment manufacturer (OEM) will install each individualhardware component to the structural door body along an assembly line.

In general, vehicle occupants are less protected against side-impactcollisions than front or rear-end collisions due to the relativethinness of the motor vehicle door. The door body itself can be forcedinto the passenger compartment, since the door body typically absorbsonly a limited portion of the collision energy. Additionally, rigidhardware components that are mounted between the outer and inner sheetmetal panels can also be forced into the passenger compartment. Toimprove safety in side-impact collisions, the vehicle door is typicallyreinforced by strengthening the sheet metal panels, or by mountingreinforcing structures such as crash beams to the door body.Additionally, one or more energy absorbing foam blocks are typicallymounted between the inner and outer sheet metal panels to reduce theseverity of a side-impact collision.

The conventional installation of the hardware and safety components has,however, several drawbacks. First, a high assembly cycle is required toassemble the door in this fashion since installation of each hardwareand safety component is a separate task requiring human effort. Hardwarecomponents must be mounted to the door body and then interconnected.Second, operability of the hardware components cannot be determineduntil the respective components are installed onto the door. Thus, timeand labor may be wasted installing inoperable or ill-fitted components.Finally, additional time is required to inventory each hardwarecomponent as it arrives at the OEM to ensure that all of the hardwarecomponents are available for assembly.

Pre-assembled door modules have been proposed to overcome some of thedeficiencies of conventional door assembly methods. A door moduletypically involves using a carrier plate to partially assembly andorientate hardware components thereto prior to installation to thestructural door body. One disadvantage associated with such door modulesis that once the door module is installed to the door, the carrier bodytypically serves little or no purpose since all of the hardwarecomponents are eventually securely fastened to the structural door bodyand the door module itself does little or nothing to strengthen the doorbody. Another disadvantage associated with such door modules is that thedoor modules themselves are very labour intensive and require a largenumber of parts and steps to assemble before they can be delivered tothe OEM.

It is therefore desired to provide a door module that adds structuralsupport to a motor vehicle door body, provides greater protection topassengers, and is easy to assemble at an OEM plant.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention, there is provideda structural door module for a motor vehicle door body. The structuraldoor module includes a carrier plate forming a first and second surface,and a plurality of door hardware components are mounted to at least oneof the first and second surface in a pre-configured orientation. Thestructural door module also includes an arm rest support that isintegrally formed from and extends out from the first surface of thestructural plate and forms a hollow in the second surface. Preferably,an array of crumple zones are provided around the surface of the armrest support to minimize the dangers of a side-impact collision.

According to a second aspect of the present invention, there is provideda structural door module for a motor vehicle door body. The structuraldoor module includes a carrier plate forming a first and second surface,and a plurality of door hardware components are mounted to at least oneof the first and second surface in a pre-configured orientation. Anenergy absorption block is integrally formed from the first and secondsurface of the carrier plate. Preferably, the energy absorbing block isa series of raised and lowered terrace portions arranged concentricallyand spaced apart by wall portions of the energy absorbing block.

According to a third aspect of the present invention, there is provideda structural door module for a motor vehicle door body. The structuraldoor module includes a carrier plate forming a first and second surface,and a plurality of door hardware components are mounted to at least oneof the first and second surface in a pre-configured orientation. Ahandle support is integrally formed from the carrier plate. The handlesupport provides a cavity to receive a door handle assembly on the firstsurface.

According to a fourth aspect of the present invention, there is provideda structural door module for a motor vehicle door body. The structuraldoor module includes a carrier plate forming a first and second surface,and a plurality of door hardware components are mounted to at least oneof the first and second surface in a pre-configured orientation. A drumhousing is integrally formed from one of the first and second surface,and includes a shaft passage extending from the first surface to thesecond surface. A rail is mounted to the same one of the first andsecond surface as the drum housing and includes a flange that is mountedat least partially over the drum housing. A lift member is slidablymounted on the rail. A motor is mounted to the carrier plate on thesurface opposite the drum housing. The motor includes a drive shaft thatextends through the shaft passage in the drum housing. A cable drum ishoused within the drum housing and is retained there within by theflange on the rail. The cable drum is rotatably mounted to the driveshaft between the carrier plate and the at least one rail.

According to a fifth aspect of the present invention, there is provideda structural door module for a motor vehicle door body. The structuraldoor module includes a carrier plate forming a first and second surface,and a plurality of door hardware components are mounted to at least oneof the first and second surface in a pre-configured orientation. A latchpresenter is integrally formed from the first surface and a glass guideis integrally formed from the edge of the latch presenter.

According to a sixth aspect of the present invention, there is provideda structural door module for a convertible motor vehicle door body. Thestructural door module includes a carrier plate forming a first andsecond surface, and a plurality of door hardware components are mountedto at least one of the first and second surface in a pre-configuredorientation. A window regulator is mounted to one of the first andsecond surface, and includes a first and a second rail. A glass guidechannel is mounted to each of the first and second rail. Each of thefirst and second rail mounted at a first end to the carrier plate. Eachrail is provided with an independent rail adjustment means operable tochange the displacement of its respective rail and the mounted glassguide channel relative to the carrier plate.

The present invention provides a structural door module for a motorvehicle door body, comprising a carrier plate with a plurality of doorhardware components mounted to the dryside and wetside surfaces of thecarrier plate. The carrier plate includes a number of preformedcomponents that allow door subsystems to be pre-mounted to the doormodule and tested prior to mounting the structural door module in themotor vehicle door body. An energy absorbing area is molded into thecarrier plate. Additionally, a protruding arm rest support is designedto collapse during a side-impact collision.

A second embodiment provides a structural door module for a convertiblevehicle door body, comprising of a carrier plate with a plurality ofdoor hardware components mounted to the dryside and wetside surfaces ofthe carrier plate. A pair of glass guide channels are mounted to tworails on the window regulator. An integrally formed mirror flag isprovided on one of the two glass guide channels. A latch presenter ismounted to the other of the two glass guide channels. Each of the tworails is provided with an independent adjustment means that allows therail to be moved closer to or farther away from the carrier plate.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the present invention will now be described, byway of example only, with reference to the attached Figures, wherein:

FIG. 1 is an exploded front perspective view of a structural door moduleaccording to a first embodiment of the invention;

FIG. 2 is an exploded rear perspective view of the structural doormodule shown in FIG. 1;

FIG. 3 is a front perspective view of the structural door module shownin FIG. 1;

FIG. 4 is a rear perspective view of the structural door module shown inFIG. 2;

FIG. 5 a is a detail view of an arm rest support and an energy absorbingblock located on the structural door module shown in FIG. 3;

FIG. 5 b is a detail view of the energy absorbing block located on thestructural door module shown in FIG. 4;

FIG. 6 a is an exploded front detail view of an inner handle supportlocated on the structural door module shown in FIG. 1;

FIG. 6 b is an exploded rear detail view of the back of the inner handlesupport located on the structural door module shown in FIG. 2;

FIG. 7 a is a front detail view of the cable drum housing located on thestructural door module shown in FIG. 1;

FIG. 7 b is a front detail view of a portion of the mounted windowregulator located on the structural door module shown in FIG. 3;

FIG. 8 is a front perspective view of a latch presenter located on thestructural door module shown in FIG. 3;

FIG. 9 is a front perspective view of a structural door module accordingto a second embodiment of the invention;

FIG. 10 is a rear perspective view of the structural door module shownin FIG. 9.

FIG. 11 is a cross-section of a portion of the structural door moduleshown in FIG. 9;

FIG. 12 is a side perspective view of the structural door module shownin FIG. 9; and

FIG. 13 is a detail view of a portion of a window regulator located onthe structural door module shown in FIG. 9.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-8 show a first embodiment of the invention, and FIGS. 9-13 showsa second embodiment of the invention.

FIGS. 1 to 4 show a structural door module 20, which includes aplurality of hardware subsystems mounted to or otherwise integrated witha carrier plate 22, and discussed in greater detail below. FIGS. 1 to 2show an exploded perspective view of the structural door module 20 andFIGS. 3 to 4 are an assembly view of the structural door module 20.Carrier plate 22 provides opposing first and second surface, hereafterreferred to as the “dryside” and “wetside” surfaces respectively. Shownin FIG. 1, the dryside surface of carrier plate 22 faces the interior ofthe vehicle when mounted to a motor vehicle door body (not shown).Conversely, as shown in FIG. 2, the wetside surface of carrier plate 22faces the exterior of the vehicle when mounted to a motor vehicle doorbody (not shown). Hardware subsystems that are typically pre-mounted tocarrier plate 22 include a window regulator assembly 24, a latchassembly 26, a handle assembly 28, a speaker assembly 30 and anelectrical harness assembly 32.

Carrier plate 22 includes a number of integrally formed or moldedcomponents. Integrally formed components on carrier plate 22 includesupport ribs 33, an integral arm rest support 34, at least one integralenergy absorption block 36, an integral inner handle support 38, anintegral drum housing 40, an integral latch presenter 42, harness clips44, and a speaker housing 46. A plurality of fastener holes 48 spacedapart around the surface of carrier plate 22 provide a means to attachstructural carrier plate 22 to the motor vehicle door body through theuse of carriage bolts, screws or the like. A plurality of access holes49 are formed in carrier plate 22 to allow passage of articulating rodsand electrical cables (both described in greater detail below).Preferably, a water-sealing bead 50 is formed around the perimeter ofcarrier plate 22 on the wetside surface. The sealing bead 50 engages theinner wall of the motor vehicle door body, providing a watertight sealfor structural door module 20. Water sealing bead 50 can be integrallyformed from carrier plate 22 or, alternatively, water sealing bead 50can be affixed to carrier plate 22 as a foam adhesive or the like.Preferably, a sealing gasket 51 is mounted over access holes 49 foradditional weather proofing.

Carrier plate 22 is preferably manufactured from a composite materialand molded into the desired shape. In the preferred embodiment, carrierplate 22 is manufactured using a 40% polypropylene matrix with glassreinforcement fibers. Other matrix materials will occur to those ofskill in the art. Other reinforcement fibers contemplated includeKevlar, carbon fibers, and hemp, and other reinforcement materials willoccur to those of skill in the art.

The support ribs 33 are a series of integrally formed ridges thattraverse portions of the dryside and wetside surfaces of carrier plate22, reinforcing carrier plate 22. The inherent material strength of thecomposite material used in carrier plate 22 combined with support ribs33 reinforces door module 20, and thus strengthens the motor vehicledoor body when mounted thereto.

Referring additionally to FIGS. 5 a and 5 b, arm rest support 34 isshown in greater detail. Arm rest support 34 is integrally formed withthe carrier plate 22 and projects outwards generally perpendicularlyfrom the dryside, forming an arm rest hollow 35 on the wetside surfaceof carrier plate 22. Arm rest support 34 is configured to mount a pieceof armrest trim (not shown) on the interior of the motor vehicle doorbody. At least one fastener hole 37 is provided on the arm rest support34 to secure the arm rest trim using a conventional fastener such as ascrew, bolt or the like. The exact shape of arm rest support 34 can varyin order to accommodate differently shaped pieces of arm rest trim.Although the current embodiment uses only one arm rest support 34, it iscontemplated that carrier plate 22 could provide two or more arm restsupports 34 to mount a piece of arm rest trim.

During a side-impact collision, arm rest support 34 is designed tocollapse in upon itself, absorbing kinetic energy as arm rest support 34pushes into the passenger compartment of the vehicle. As can be seenclearly in FIG. 5 a, an array of beveled crumple zones 54 are providedspaced across the horizontal and vertical surface of arm rest support34. In the presently illustrated embodiment, crumple zones 54 arediamond-shaped and straddle the corners between horizontal and verticalportions of arm rest support 34. Crumple zones 54 comprise thinnerportions of arm rest support 34 that are weaker than the thicker,non-crumple zone portions. In the presently illustrated embodiment, thethickness of crumple zones 54 is 0.5 mm and the thickness of thenon-crumple zone portions of arm rest support 34 is 2 mm. Dimensions canvary due to differing force requirements for different models of doormodules. Alternatively, crumple zones 54 could be holes spaced acrossarm rest support 34. Crumple zones 54 are engineered to buckle undercompression, but remain firm under tension and bending loads. Whensubjected to a violent compression force, crumple zones 54 buckle,causing arm rest support 34 to partially compact into hollow 35, ratherthan remain rigid. In the illustrated embodiment, arm rest support 34requires a force of at least 2000 N maintained over a displacement of aminimum of 38 mm to begin collapsing. Other embodiments of the inventionwill compact under different loads. In addition to collapse upon impact,arm rest support 34 is capable of withstanding the rigors ofconventional use. For example, when a heavy load is applied to theattached armrest (as would be caused by an occupant leaning on thearmrest trim), the orientation of crumple zones 54 cause arm restsupport 34 to buckle slightly rather than break. In the illustratedembodiment, arm rest support 34 is designed to support a load of up toapproximately 100 kg. Arm rest support 34 is also designed to withstanda force of approximately 196 N (as would be caused by an occupantslamming the motor vehicle door shut or pushing the door open by thearmrest trim).

As mentioned earlier, at least one integral energy absorption block 36is formed from structural carrier plate 22. Energy absorption block 36is structurally stiff across its length and width but designed tocrumple upon perpendicular impact (i.e., perpendicular to the generalplane of carrier plate 22), absorbing energy from the collision. As canbe clearly seen in FIGS. 5 a and 5 b, energy absorption block 36 ismolded into a series of concentric raised and lowered terraces 56 thatfirst extend out from the dryside of carrier plate 22 and then recedeinto carrier plate 22 forming a hollow 58. Terraces 56 are spaced apartby contoured wall portions 60. Adjacent wall portions 60 are connectedto each other by trough-shaped web portions 61. Web portions 61 arepreferably thinner than the other portions of energy absorption block 36as to tear more easily. Impact causes energy absorption block 36 tocollapse inwards into hollow 58 prior to intruding into the passengercompartment of the vehicle. As each terrace 56 collapses into hollow 58,the material of carrier plate 22 shears along web portions 61. In theillustrated embodiment, energy absorbent block is required to maintain aforce of at least 6000 N maintained over a minimum displacement of 55 mmto begin collapsing. Again, other embodiments of the invention havingdifferent dimensions and/or block geometry will collapse under differentamounts of force.

Referring additionally to FIGS. 6 a and 6 b, inner handle support 38 isshown in greater detail. Inner handle support 38 forms an integrallyformed handle chamber 62 and lock switch chamber 64 that are both opento the dryside. Handle chamber 62 is adapted to receive a handle 66 andincludes two opposing pivot holes 68 to pivotally mount handle 66 usingpins, screws or the like. Handle 66 further includes a hinged mount 67that secures handle 66 to inner handle support 38, while stillpermitting handle 66 to pivot within handle chamber 62, typically usinga screw fastener. Lock switch chamber 64 is adapted to receive a doorlock switch 70, which is held in place by detent tabs, screws or thelike. Handle chamber 62 further includes a connecting rod passage 71between the dryside and the wetside of carrier plate 22. An articulatedrod 72 a (not shown in FIGS. 6 a and 6 b) passes through rod passage 71to connect a rod arm 73 extending from handle 66 to latch assembly 26(described in greater detail below). Lock switch chamber 64 furtherincludes electrical access passage 74. A cable from electrical harnessassembly 32 (not shown in FIGS. 6 a and 6 b) passes through electricalaccess passage 74 and plugs into a socket (not shown) on door lockswitch 70, and is described in greater detail below with reference toelectrical harness assembly 32. Inner handle support 38 is furtheradapted to receive a fitted piece of trim (not shown) on the drysidethat includes an opening to provide access to handle 66 in the passengercompartment. As such, the entire handle assembly 28 can be assembled aspart of structural door module 20 prior to being mounted to a motorvehicle door body, reducing vehicle assembly time. Additionally, handleassembly 28 can be pre-tested before being mounted to a motor vehicledoor body.

Referring back to FIGS. 1 to 4, in the illustrated embodiment, windowregulator assembly 24 includes two rails 76, mounted in parallel at bothends to carrier plate 22. An opposing pulley 78 is rotatably mounted ateach end of both rails 76. Each rail is further adapted to mount a liftmember 80 in a slidable engagement. One of the rails 76 mounted to thecarrier plate 22 has a flange situated to partially cover drum housing40. A motor 82 is mounted to the dryside of carrier plate 22 and drivesa cable drum 84. A cable 86 is threaded around the four opposing pulleys78, cable drum 84 and connected to the two lift members 80.

As mentioned earlier, drum housing 40 is integrally formed on thewetside surface structural carrier plate 22. As can be more clearly seenfrom the detailed view of FIG. 7 b, drum housing 40 receives cable drum84 and includes a cylindrical sidewall 88. Cylindrical sidewall 88contains a gap portion 90, allowing cables 86 to wrap around cable drum84 and towards opposing pulleys 78 on the further rail 76. Centered indrum housing 40 is a shaft opening 92 (see FIG. 7A) that provides apassage between the dryside and wetside of carrier plate 22. A circulararrangement of tabs 94 allows an assembler to temporarily situate cabledrum 84 in drum housing 40 prior to being permanently coupled to motor82.

Motor 82 is coupled with a drive shaft 96 and situated so that driveshaft 96 passes through shaft opening 92. Gear teeth 98 on drive shaft96 engage cable drum 84 so that it is held in place between the carrierplate 22 and the over-mounted flange on rail 76. Drive shaft 96 extendsthrough and is freely rotatable within a shaft opening 100 in theover-mounted rail 76. A cable from electrical harness assembly 32 plugsinto a socket (not shown in FIG. 7 a or 7 b) on motor 82, and isdescribed in greater detail below with reference to electrical harnessassembly 32. As such, the entire window regulator assembly 24 can beassembled on carrier plate 22 as part of structural door module 20,reducing vehicle assembly time. Additionally, window regulator assembly24 can be pre-tested before being mounted to a motor vehicle door body.

As mentioned previously, a latch presenter 42 is integrally formed froman edge of structural carrier plate 22. As can be more clearly seen fromFIG. 8, latch presenter 42 forms a box-like compartment 102 on thewetside surface of carrier plate 22. The sidewall of compartment 102 isopen on one side to receive and mount latch assembly 26. A rod passage103 in the opposing sidewall of compartment 94 allows articulated rod 72a to pass into compartment 102 and connect latch assembly 26 to rod arm73. An articulated rod 72 b also passes through rod passage 103 andterminates in a lock status indicator 105 (not shown in FIG. 8).

A cable from electrical harness assembly 32 plugs into a socket (notshown) on latch assembly 26, and is described in greater detail belowwith reference to electrical harness assembly 32. As such, the entirelatch assembly 26 can be assembled on carrier plate 22 and connected tohandle assembly 28 as part of structural door module 20 prior to beingmounted to a motor vehicle door body, reducing vehicle assembly time.Additionally, latch assembly 26 can be pre-tested before being mountedto a motor vehicle door body.

Extending out from the surface of latch presenter 42 and displaced awayfrom the wetside surface of carrier plate 22 is an integrally formedglass channel 104. Glass channel 104 provides a C-shaped channel thatruns generally parallel to rails 76 adapted to provide additionalstabilization for a window glass (not shown) mounted to window regulatorassembly 24. Preferably, weather stripping (not shown) is added to glasschannel 104 to provide a water-tight seal around the window pane.

The carrier plate includes an integrally formed outside handle base 106that extends substantially perpendicular to glass channel 104. Outsidehandle base 106 is exposed to the outer surface of the vehicle door bymeans of an opening (not shown) formed in the outer sheet metal panel ofthe motor vehicle door. Outside handle base 106 provides an linked end107 which is contiguous with the glass run channel and a free end 109intended to be fastened to the outer sheet metal layer of the vehicledoor using screws or the like. The outside handle base 106 includes acavity 108A enabling an outer door handle (not shown) to be insertedtherethrough for connection to a U-shaped biased hinge mechanism 108mounted to linked end 107. The outer door handle preferably seats in afeature 108C of the hinge mechanism but may be connected to the hingemechanism 108 using other conventional means. The hinge mechanism 108includes an arm 108 d which swings as the U-shaped part of the hingemechanism pivots in response to actuation of the outer door handle. Thearm 108 d is in turn connected to latch assembly 26 by a rod 110 a whichactivates a latch outer door release lever. Rod 110 b connects a doorhandle key cylinder (not shown) to the latch assembly, as known in theart per se.

Referring back to FIGS. 1 to 4, electrical harness assembly 32 includesa plurality of cables 112 originating from a face boot 114. Cables 112provide signals and power to all the electrically-driven subsystemsmounted to structural door carrier 20, including window regulatorassembly 24, latch assembly 26, inner handle assembly 28 and speakerassembly 30. Each cable 112 ends in an electrical controller 116. Eachelectrical controller 116 is adapted to plug directly into acomplementary socket on its designated subsystem. For example,electrical controller 116 a plugs into a socket on motor 82 to providepower to window regulator assembly 24, electrical controller 116 c plugsinto a socket on latch assembly 26, electrical controller 116 b plugsinto a socket on door lock switch 70 to provide power to inner handleassembly 28, and electrical controller 116 d plugs into a socket onspeaker assembly 30. Other electrical controllers 116 can be provided topower other subsystems mounted to structural door module 20. By usingelectrical controllers 116 that plug directly into their designatedsubsystem, wiring time is minimized. In addition, each electricalcontroller 116 and complementary electrical socket can differ in shapefrom each other electrical controller 116-electrical socket pair as toprevent miswirings. Harness clips 44 on the surface of carrier plate 22hold electrical cables 112 in place. Preferably, harness clips 44 areintegrally formed from the surface of carrier plate 22 as to eliminatethe need to separately mount harness clips 44 to carrier plate 22.

FIGS. 9 and 10 show a structural door module 120 that embodies a secondaspect of the invention. The structural door module 120 is particularlyuseful for a convertible vehicle door and includes a carrier plate 122.Carrier plate 122 includes a number of integrally formed or moldedcomponents. Integrally formed components on carrier plate 122 includesupport ribs 133, an integral arm rest support 134, at least oneintegral energy absorption block 136, an integral inner handle support138, harness clips 144, and speaker housing 146. A plurality of fastenerholes 148 spaced apart around the surface of structural carrier plate122 provide a means to attach structural carrier plate 122 to theconvertible vehicle door body through the use of carriage bolts, screwsor the like. Preferably, a water-sealing bead 150 is formed around theperimeter of carrier plate 22 on the wetside surface. The sealing bead150 engages the inner wall of the convertible vehicle door body,providing a watertight seal for structural door module 120. Watersealing bead 150 can be integrally formed from carrier plate 122 or,alternatively, water sealing bead 150 can be affixed to carrier plate122 as a foam adhesive or the like.

A window regulator assembly 154 is mounted to the wetside surface ofcarrier plate 122. Window regulator assembly 154 includes a pair of liftmembers 156 slidably mounted to parallel first and second rails 158.Each of first and second rails 158 is mounted to carrier plate 122 by ajack screw 160 secured near one end of first and second rails 158. Jackscrews 160 provide for cross-car adjustment of the window glass.Referring additionally to FIG. 11, each of first and second rails 158includes a locking nut 161 to securely mount jackscrew 160 to rail 159.Jack screws 160 extend through carrier plate 122 and are mounted tocarrier plate 122 via an adjusting nut 163. By rotating adjusting nut163 clockwise or counterclockwise, jackscrew 160 is displaced furthertowards either the dryside or the wetside, adjusting the positioning ofthe rail 158 relative to carrier plate 122. Thus, the position of amounted window glass (not shown) can be easily adjusted. Each of thejackscrews 160 can be adjusted independently of the other, allowing fora more precise fit.

Referring back to FIGS. 9 and 10, a C-shaped front guide channel 162 andan opposing C-shaped rear guide channel 164 provide additional stabilityfor a mounted window glass (not shown). An integrally formed bracket 166on front guide channel 162 and rear guide channel 164 mounts front guidechannel 162 and rear guide channel 164 to their respective first andsecond rail 158. Brackets 166 can be mounted to first and second rail158 using clips, screws or other conventional mounting means. Each offront guide channel 162 and rear guide channel 164 are further mountedto their respective first and second rail 158 by a dual link bracket168. Each dual link bracket 168 is comprised of a first portion 170, asecond portion 172 and a middle portion 174. First portion 170 isintegrally formed at one end from one of front guide channel 162 andrear guide channel 164 and extends at a perpendicular thereto. Secondportion 172 is rotatably connected at a one end to one of first andsecond rails 158. Middle portion 174 is rotatably connected at both endsto first portion 170 and second portion 172. Given the adjustablemounting of first and second rails 158 on jack screws 160, combined withthe pivotal mounting of the dual link brackets 168, the position of awindow glass can be shifted around in a convertible door frame.

A mirror flag stem 176 is integrally formed from one end of front guidechannel 162. Mirror flag stem 176 is adapted to receive a side mirrorassembly (not shown) on the exterior of the motor vehicle door body.Mirror access holes 178 provide an opening to interconnect the mirrorassembly with electrical cables 112 (for mirror assemblies that areelectrically steerable or heated or to an actuating rod (for mirrorassemblies that are manually steerable). As such, the entire mirrorassembly can be assembled and aligned as part of structural door module120 prior to being mounted to a motor vehicle door body, reducingvehicle assembly time. Additionally, the mirror assembly can bepre-tested before being mounted to a motor vehicle door body.

Referring additionally to FIGS. 12 and 13, a latch presenter 180 ismounted to rear glass guide channel 164 near bracket 166. Latchpresenter 180 can be mounted to rear guide channel 164 using clips,screws or other conventional mounting means. A latch assembly 126 ismounted to latch presenter 180. Once window regulator assembly 154 ismounted to carrier plate 122, latch assembly 126 can be interconnectedto the inner and outer door handles (not shown) and electrical cables112 (not shown), reducing vehicle assembly time. Additionally, latchassembly 126 can be pre-tested before being mounted to a motor vehicledoor body.

An outside handle base 182 is formed from latch presenter 180. Outsidehandle base 182 is adapted to pass through an opening in the motorvehicle door body (not shown) and to be exposed to the outer surface ofthe vehicle. Outside handle base 182 provides an attached end 184 and afree end 186. A hinge mount 188 is fitted around attached end 184. Anouter door handle (not shown) complementary to outside handle base 182can be pivotally mounted to hinge mount 188 using conventional means.Hinge mount 188 connects to latch assembly 126 by a pair of outerarticulating rods 190 (not shown).

The above-described embodiments of the invention are intended to beexamples of the present invention and alterations and modifications maybe effected thereto, by those of skill in the art, without departingfrom the spirit of the invention.

What is claimed is:
 1. A structural door module for a motor vehicle door body, comprising: a carrier plate forming a first and second surface; a plurality of door hardware components mounted to at least one of the first and second surface in a pre-configured orientation; and a handle support integrally formed from the carrier plate, the handle support providing a cavity to receive a door handle assembly on the first surface.
 2. The structural door module of claim 1, wherein the door handle assembly is mounted to the handle support prior to the door module being mounted to the motor vehicle door.
 3. The structural door module of claim 2, wherein a latch assembly is mounted to the carrier plate and the door handle assembly is connected to the latch assembly prior to the door module being mounted to the motor vehicle door.
 4. A structural door module for a motor vehicle door body, comprising: a carrier plate forming a first surface and a second surface; an inner handle support forming a handle chamber that is open from the first surface away from the second surface, wherein the handle chamber includes an inner handle support to receive a handle, the handle forming part of a handle assembly.
 5. The structural door module of claim 4, wherein the handle mount comprises two opposing pivot holes to pivotally mount handle using pins, screws or the like.
 6. The structural door module of claim 4, further comprising a lock switch chamber that is open from the first surface away from the second surface.
 7. The structural door module of claim 4, wherein the handle assembly further includes a hinged mount that secures the handle to the inner handle support, while permitting the handle to pivot within the handle chamber.
 8. The structural door module of claim 6, wherein the lock switch chamber is adapted to receive a door lock switch.
 9. The structural door module of claim 4, wherein the handle chamber further includes a connecting rod passage open between the first surface and the second surface of carrier plate, and an articulated rod passing through the rod passage to connect a rod arm extending from the handle to a latch assembly connected to the carrier plate.
 10. The structural door module of claim 6, wherein the lock switch chamber further includes an electrical access passage, and a cable from an electrical harness assembly passing through the electrical access passage to door lock switch in the lock switch chamber.
 11. The structural door module of claim 4, wherein the inner handle support is further adapted to receive a fitted piece of trim on the first surface that includes an opening to provide access to handle through the fitted piece of trim.
 12. The structural door module of claim 4, wherein the handle assembly is assembled as part of the structural door module prior to the structural door module being mounted to a motor vehicle door body.
 13. The structural door module of claim 12, wherein the handle assembly is pre-tested on the structural door module before the structural door module is mounted to a motor vehicle door body. 